Manufacture of bifold doors

ABSTRACT

Hinging of door halves by pressing hinges having fastening projections depending therefrom onto a pair of door halves. Hinge blanks are oriented and stamped to form the depending fastening projections and, thus stamped and oriented, are fed to the pressing zone for application to the doors. The door halves are fed in side-by-side relationship through the hinge pressing zone.

llnited States Patent Fritze et all. 45 May 23, 1972 54] MANUFACTURE OF BIFOLD DOORS 3,393,444 7/1968 Peters et a1. ..29/442 3,100,301 8/1963 Black Inventors: William Fritze, Hillsdale; Wallace 3,008,143 11/1961 Bagwell et al Scarlet, KentWOOd, both of Mich- 1,864,865 6/1932 Smith ..227/48 .[73] Assignee: fivlgouth Flush Door, Inc., Hlllsdale, Primary fimminer .nlomas H Eager Attorney-John E. McGarry [22] Filed: July 1, 1970 [57] ABSTRACT 21 Appl. No.: 51,512

Hinging of door halves by pressing hinges having fastening projections depending therefrom onto a pair of door halves. [52] US. Cl. ..29/429, 29/21 1 D, 29/442 Hinge blanks are oriented and stamped to form the depending [51] Int. Cl. ..B23p 19/00, B23q 7/10, B23p 1 1/00 fastening projections and, thus stamped and oriented, are fed [58] Field of Search ..29/429, 442, 211, 208, 211 D, to the pressing zone for application to the doors. The door 29/208 D; 227/152, 93, 48 halves are fed in side-by-side relationship through the hinge pressing zone. 56 1 References GM 28 Claims, 13 Drawing Figures UNITED STATES PATENTS Patented May 23, 1972 3,664,009

r SheetS-Sheet 1 INVENTOR. WILUAM R. FR" 25 WALLACE W. SCARLETT QYEJZM Patented ay 23, 1972 3,664,0U9

7 Sheets-Sheet 2 l NVEN TOR WiLLlAM R. FRH'ZE WALLACE W. SCARLETT BY gaiwiflw Patented May 23, 1972 3,664,009

7 Sheets-Sheet 5 FIG. 7

INVENTOR. WILLIAM R. FRH'ZE WALLACE W. SCARLETT Patented May 23, 1972 7 Sheets-Sheet 7 242 I as ':CONTROL CENTER FIG. u

' YNV'ENTOR. WILUAM R. FRH'ZF.

zao

' WALLACE W- SCARLETT BY FIG. l0

MANUFACTURE OF BIIFOLD DOORS This invention relates to the manufacture of hinged articles such as bifold doors. In one of its aspects, it relates to an apparatus for applying hinges to a pair of planar wooden members to produce a bifold door.

In another of its aspects the invention relates to a method of manufacturing bifold doors.

In the manufacture of bifold doors, pairs of planar door halves are hinged together at the abutting edges thereof by conventional leaf hinges having a barrel between opposite leaf members. One leaf is fixed to each of the doors through wood screws. The screws are put into the doors in a hand operation which takes considerable time. The production of the doors is dependant on the rate at which the hinges can be applied to the doors. Generally the rate of door production using two men on the hinge applying operation is about 80 bifold doors per hour.

It has been proposed to mechanize this operation and apply the screws mechanically. However, the tolerances in the placement of the screw holes in the hinge blanks are too large to permit accurate placement of screws in the holes in a mechanized operation. If the tolerances of the holes are kept to a minimum for the mechanized operation, then the cost of the hinge blank rises so as to make the mechanized operation unprofitable.

It has now been discovered that this hinge applying operation is quite readily adaptable to a mechanized operation by providing hinges with fastening projections depending therefrom, which hinges are pressed onto the door halves, thereby eliminating the screw applying operation.

By various aspects of this invention one or more of the following, or other, objects can be obtained.

It is an object of this invention to provide a mechanized hinge applying operation in the production of bifold doors.

It is a further object of this invention to provide a method and apparatus for the production of bifold doors and the like at greatly improved rates of production.

It is a further object of this invention to provide a hinge applying operation for joining pairs of planar wooden members wherein the time consuming screw applying operation is eliminated.

It is yet another object of this invention to provide a method and apparatus for the production of bifold doors wherein hinges are oriented and indexed by the barrel for feeding in a predetermined orientation to a hinge applying operation.

Other aspects, objects and the several advantages of this invention are apparent to one skilled in the art from a study of this disclosure, the drawings, and the appended claims.

According to the invention, there is provided a method and apparatus for the manufacture of bifold doors having door halves hinged together at the abutting edges thereof. The door halves are fed in juxtaposed relationship to a hinge applying area. The hinges have a pair of leaves separated by a barrel to permit rotation of one of the leaves with respect to the other and each of the leaves has fastening members depending therefrom. The hinges are fed to the hinge applying area above the door halves with the depending members and the barrel in a predetermined orientation or relationship with respect to the door halves. The hinges are quickly and simply pressed onto the door halves with one leaf of each hinge being secured by the depending fastening members to each of the door halves.

The invention will now be described with reference to the accompanying drawings in which:

FIGS. 1A and 1B are a plan view of a hinge applying apparatus;

FIGS. 2A and 2B are a side elevational view thereof;

FIG. 3 is a cross sectional view through lines III-III of FIG. 18;

FIG. 4 is a partial cross sectional view through lines IV-IV of FIG. 1A illustrating a portion of the hinge orienting and feeding apparatus.

FIG. 5 is a partial cross sectional view through line V-V of FIG. 1A illustrating another portion of the hinge feeding and orienting apparatus;

FIG. 6 is a perspective view of the hinge feeding and orienting apparatus;

FIG. 7 is a partial cross sectional view through lines VII- VII of FIG. 1A illustrating a portion of the device for feeding the hinge blanks to the stamping press;

FIG. 8 is a partial sectional view taken along lines VIII- VIII of FIG. 7;

FIG. 9 is a partial section view taken along lines lX-IX of FIG. 1A illustrating the mechanism for feeding the stamped hinges to the hammer press, and also illustrating the hammer press;

FIG. 10 is a partial cross sectional view through lines X-X of FIG. 9; and

FIG. 11 is a schematic block diagram of the control system used in the apparatus illustrated in FIGS. 1 through 10.

Referring now to the drawings and to FIGS. 1A, 1B, 2A and 2B in particular, there is shown a hinge applying apparatus having a feed conveyor 12, a hopper 14 for storage of door halves, a shuttle platen 16 for transferring the doors from the hopper to a hinge hammer press 18. Hinge blanks 26A are oriented and fed from a bowl feed 20 to a stamping press 22 where the hinge blanks are stamped to form depending nails thereon. The stamped hinges 26 are then fed to the hinge hammer press 18 wherein they are hammered or pressed onto the door halves 24 positioned therebeneath. After the proper number of hinges have been applied to the doors 24, they are carried by the shuttle platen 16 to the end of the line and ejected onto a discharge conveyor 28.

Throughout this specification the number 26A is used to designate the hinge blanks and 26 is used to designate the hinges having the fastening projections depending therefrom.

The feed conveyor 12 is formed from a plurality of rollers 30 which are journaled in plates 32. Horizontal support members 34 and vertical support members 35 form a table for the rollers 30. A separator plate 36 maintains a separation between the doors on either side of the feed conveyor 12. Each of the rollers 30 is canted slightly so that the doors are moved toward the separator plate 36 as they are conveyed toward the hopper.

The rollers 30 are driven by a conventional belt drive 38 which in turn is driven by a motor 40 through conventional pulleys (not shown).

A pair of feed rolls 42 and 44 are supported at the exit end of the feed conveyor 12 by a table formed by horizontal supports and legs 52. In addition, the upper roller 42 is supported by an arm 46 which is pivotably secured to a superstructure formed by top braces 53, cross braces 56 and legs 54. The legs 54 are supported by and joined to the horizontal supports 50. A belt drive 48, which is connected through means (not shown) to motor 40, drives the rollers 42 and 44.

Reference is now made to FIGS. 1B, 2B and 3. The hopper 14 is formed by side walls 58 and 60 and a central divider 62. Cylinders 64, having piston rods 68, are supported by brackets 66 at the outer portions of the side walls 58 and 60. The piston rods 68 extend through the side walls 58 and 60 and contact the lowermost doors 24 in the hopper to hold the doors within the hopper until it is desirable to release them (see FIG. 3).

Each of the side walls 58 and 60 are supported at the forward end by blocks 70 on an acme threaded rod 72. In addition, the side walls can be supported at this forward end by guide blocks 74 and guide rods 76. The threaded rod 72 at the forward end is joumaled in the legs 54 and the guide rods 76 are secured to the legs 54. The acme threaded rod 72 has threads on one end turning in one direction and threads on the other end turning in the opposite direction. Thus, by rotation of the threaded rod 72 by a handle or other suitable means, the side walls 58 and 60 can be made adjustable toward and away from the center divider 62 so that the hopper can be adjustable for doors of different width. A similar adjustable arrangement is provided at the other end of the hopper. A plate 71 is fixed to the bottom of the back or feed end of each sidewall 58 and 60. Each plate 71 is secured to a block 70A which threadably engages a second acme threaded rod 72A. The acme threaded rod 72A is turned to adjust the position of the back end of the hopper side 68 and 60 with respect to the center divider 62.

End stops 77 are positioned at the forward end of the hopper at an end guide for the doors within the hopper. These end stops 77 extend to the bottom of the hopper but terminate a sufficient distance above the shuttle platen 16 to permit a pair of door halves 24 on the shuttle platen to pass therebeneath. The end stops 77 are rigidly secured to a cross brace 78 having end braces 79 with members threadably engaging threaded rods 80. The end braces 79 are moved by rotation of the rods 80 to thereby move the end stops 77 longitudinally within the hopper to adjust the hopper length for different length doors. A locking means in the form of an adjustable wire 81, which binds the end braces 79 against the guide rods 80, is provided to fix the end stops 77 in adjusted position. The guide rods 80 are journaled in a pair of cross braces 56.

Means are provided to rotate the threaded rods 80 for movement of the end stops 77 within the hopper. Such means include a rod 132 having a crank 136 and bevel gears 130 at one end thereof. The threaded rods 80 have bevel gears 134 at one end thereof which engage bevel gears 134 on the rod 132. Thus, when the adjustable wire 81 is loosened, rotation of the crank 136 will cause corresponding rotation of the threaded rods 80 to thereby move the cross brace 78 and the end stops 77 longitudinally within the hopper.

The shuttle platen 16 will now be described with reference to FIGS. 1A, 1B, 2A, 2B and 3. The shuttle platen 16 has a platform base 82 for supporting the door halves 24. Longitudinal slots 84 and 86 are provided for movement of ejector lugs 88 and 90 respectively. As seen in FIG. 3, the ejector lugs 88 and 90 project up above the slots 84 and 86 respectively and contact the rear end of the door halves 24. The ejector lugs 88 and 90 force the door to the front or forward portion of the shuttle platen where they are retained by a front stop member 92. A hydraulic cylinder 96, supported by a block 94, has a piston rod (not shown) which is secured to the front stop member 92 so as to raise and lower the same. The block 94 is secured to the front ofplatform base 82.

A pair of cylinders 98 having piston rods 102 are mounted on the sides of the platform base 82. Blocks 100 are secured to the ends of the piston rods 102 and abut the outside edges of the door halves 24. A separator blade 103 is positioned at the central portion of the platform 82 to separate the door halves 84. The cylinders 98, through the side blocks 100, force the door halves 24 together against the separator blade 103.

The platform base 82 has two sets of depending channel braces 104 with wheels 106 rotatably supported between each pair of channel braces 104. The wheels ride on rails 108 which in turn are secured on top ofl beam supports 110. The shuttle platen 16 is moved by a hydraulic cylinder 116 having a piston rod 114 which has its outer end secured to a block 102 which in turn is rigidly secured to the bottom ofthe platform base 82.

The hydraulic cylinder 116 is supported by uprights 118.

Suitable power means (not shown) such as hydraulic cylinders are provided within the platform base 82 to actuate movement of the ejector lugs 88 and 90.

One of the depending channel braces 104 has an outwardly extending cam bar 120 which extends substantially the length of the channel braces 104.

A longitudinal bar 120 is fixed beneath the platform base 82 at one side thereof through a plurality of supports 124. The longitudinal bar 122 extends substantially the length of the platform base 82 and has fixed thereon at spaced intervals a plurality of depending cam members 126. A cam member 127 is fixed on the longitudinal bar 122 and extends outwardly thereof. These cam members 126 and 127 and the cam bar 120 strike cam actuators (not shown) on limit switches (not shown) as the shuttle platen I6 is moved. The operation of the various working parts of this apparatus is controlled by these switches as will be described at a later point in this specification.

The hinge orienting and feeding device 20 will now be described with reference to FIGS. 1A, 4, 5 and 6.

The hinge orienting and feeding device is constructed from a vibratory bowl feeder having a central floor portion surrounded by a sloping peripheral portion 144 and a spiral convolute hinge orienting ramp 142. The top portion of the ramp terminates at a hinge slide 165. The convolute ramp begins at the sloping peripheral portion 144 and winds circularly around the peripheral portion 144, in an upward and outward direction. The edge of the ramp is defined by a spiral circumferential rim 158. In the first revolution, the ramp is formed by an outwardly and downwardly sloping ledge 164. Near the top portion and at the commencement of the second partial revolution of the ramp, there is formed a downwardly and inwardly sloping portion 162. An inner edge plate 152 is secured at the edge of the downwardly and inwardly sloping portion 162 to retain the hinges thereon.

A flange 146 is secured above the sloping ledge 164 and has a portion bent outwardly. This flange 146 provides an abutment to knock over any hinges which are riding on end up the ramp 142.

A first folding flange 148 is provided approximately 270 from the bottom of the ramp 142 near the sloping ledge 164 but sufficiently raised to permit a folded hinge lying flat on the ledge to pass therebetween. The function of the first folding flange 148 is to fold over a hinge leaf which may be riding upright against the side wall of the ramp.

A second folding flange 150 is secured to the ramp outwardly of the downwardly and inwardly sloping portion 164 (see FIG. 4). This flange 150 is bent upwardly and twisted inwardly so that any unfolded hinges which are lying flat on the ramp will have the outer leaf folded over so that the barrel is outwardly of the leaf portions.

At the top end of the ramp 142 a ridge 156 is formed in the center portion. The ridge raises the hinges up onto the barrels 26B. If the hinges blanks 26A are oriented with their barrels 26B outwardly, then the barrel of the hinge will fall into a groove 160 and against a fence 154 which extends inwardly from the rim 158. The groove 160 deepens as it becomes closer to the hinge slide 165. Thus, if the hinges are oriented on the ramp with the barrel 26B outwardly, the position of the blank 26A at the end of the ramp will be illustrated by the solid line in FIG. 5. The hinge will be oriented into the hinge slide with the barrel 26B downwardly. As the hinge blank moves along the ridge 156, it will be raised to the upright position for reception by the hinge slide 165.

Approximately one half of the hinges moved up the ramp will be oriented with their barrels 26B outwardly. The other half will be oriented with their barrels 26B inwardly. Accordingly, means are provided to reject those hinges with the barrels 26B facing inwardly.

The inner edge plate 152 is cut away at 153 (FIG. 6) to eject hinges which are improperly oriented on the ramp. In the event that the barrel 26B of the hinge blanks 26A is directed inwardly, the ridge will raise the hinge blanks 26A in the manner shown in phantom lines FIG. 5. When the hinge reaches the cutaway portion 153 of the plate 152., it will fall from the upper portion of the ramp and onto a lower portion of the ramp or into the peripheral sloping floor portion 144. Thus, all hinges which are fed into the slide 165 are oriented with the barrel downwardly.

Reference is now made to FIGS. 1A, 7 and 8 for a description of the mechanism by which the hinges are fed from the slide 165 and into the stamping press 22 and thence into the hammer press 18. The slide 165 has mounted at one side thereof cylinders 166 and in spaced relationship. Cylinder 166 has a piston rod 168 which extends through the side of the slide to contact hinges within the slide. Likewise, cylinder 170 has a piston rod 172 which extends through the slide 165 and contacts hinges within the slide 165. The slide 165 is formed from a U-shaped track with sufiicient width between the sides to permit the hinges to stand upright therebetween and to slide from the top of the bowl feeder down to the stamping press 22.

The cylinders 166 and 170 control the movement of the hinges to the stamping press. The piston rod 172 contacts a hinge within the slide 165 to hold it in fixed relationship therein. When it is desirable to feed a hinge into the stamping press 22, the cylinder 170 withdraws the piston rod 172 to permit the hinge to slide down towards the stamping press 22. At the same time, cylinder 166 moves piston rod 168 inwardly to contact the next hinges in the slide 165 to prevent movement of that hinge. Subsequently, piston rod 172 is extended and piston rod 168 is retracted to permit the next hinge to come down into contact with the piston rod 172. In this manner the hinges are fed seriatim to the stamping press 22.

A receiving block 174 having a longitudinal slot 176 is positioned at the base of the slide 165. The receiving block 174 has a pair of receiver walls 184 for retaining the hinge blanks 26A as they eminate form the end of the slide 165. A spreader bar 178 is supported above the receiving block 174, the spreader bar 178 having a pointed end which fits between the leaves of the hinge blanks 26A as they are moved towards the stamping press 22. The spreader bar 178 has diverging sides which force the leaves of the hinge blanks 26A apart as they move from left to right as seen in FIG. 7.

A hydraulic cylinder 183 has a piston rod 182 to which a dog 180 is fixed. The dog 180 slides within the slot 176 of the receiving block 174. The top portion of the dog contacts the barrels 26B of hinge blanks 26A to move them from the receiving block onto a die block 186. The extent of movement of the dog 180 toward the die block 186 is illustrated in phantom lines in FIG. 7. A stop 190 on the die block 186 extends above the surface thereof to restrain the lateral movement of the hinge blanks 26A as they are received on the die block 186.

The die block 186 has a barrel receiving groove 188 and a plurality of holes 187 for the formation of the nails during the stamping operation.

The stamping press 22 is of conventional design of the type which uses a fly wheel and a solenoid operated lever to engage the fly wheel and actuate the press portion. A stamping die is provided above the die block 186 with the proper die projections to stamp the nails from the hinge blanks.

Reference is now made to FIGS. 1A,8 and 9. A hydraulic cylinder 196 has a piston rod 198 to which is attached a block 194. The block 194 is positioned above and adjacent the die block 186 to push the stamped hinges 26 therefrom after completion of the stamping cycle. When the piston rod 198 is extended by the cylinder 196, the hinge 26 is pushed to the left off block 186. A pair of rails 192 have their upper ends adjacent the top of the die block 186 and the lower end terminating at the hammer press 18. Each of the rails 192 is formed from a U-shaped member bent in the same manner illustrated in FIG. 9. Two of the depending nails from hinges 26 fit within the rails 192 and maintain the hinges in a predetermined position as they are fed to the hammer press 18.

The hammer press 18 will be described with reference to FIGS. 1A,9 and 10. A support plate 204 is fixed between cross members 205 and supports a hammer cylinder 208 through brackets 210 and a plate 212. The plate 212 is firmly secured to the support plate 204 through bolts or other suitable fastening means. A piston rod 214 extends from the cylinder 208 and is joined to a magnetic hammer head 216. An opening is provided in the support plate 204 for the hammer head 216. On opposite sides of the opening in plate 204 are positioned L- shaped retainers 200 which are secured beneath the plate 204 through spring biased hinges 202. The retainers 200 are normally in the position illustrated in FIG. so as to receive a hinge 26 as it slides from the rails 192. A magnetic stop 206 is secured to the bottom of the support plate 204 adjacent the hole provided therein and opposite the rails 192.

As the hinges 26 slide down the rails 192, they are held at the edges by the retainers 200. Because of the speed of traveling down the rails 192, the hinges 20 tend to slide to the stop 206. The hinges are retained at that stop by magnets (not shown) imbedded within the stop 206. When the cylinder 208 is actuated to extend the piston rod 214, the magnetic hammer head 216 pushes the hinges l6 downwardly with respect to the support plate 204. This downward movement causes the retainers 200 to rotate about the hinges 202 to release the hinge 26. The hinge 26 is then held onto the hammer head 216 by magnets (not shown) which are embedded therein. The hammer continues its downward movement until the hinges are applied to the doors with the nails penetrating the doors and firmly securing the hinge leaves to the door.

Although not specifically illustrated in the drawings, the magnetic hammer head 216 is of sufficient dimension to maintain the retainers in their outward position at the bottom of the stroke where the hinges are applied to the doors. When the hammer is retracted to the position illustrated in FIG. 10. the retainers 200 return to the position illustrated in F IO. 10.

Reference is again made to FIGS. lAand 2A. At the forward end of the rails 108 there are provided power rolls 218 and 220 which are driven by a suitable power means (not shown). The power roll 220 is supported by a resiliently biased arm 222. A horizontal support member 224 pivotably supports the arm 222. Upright frame member 226 are joined at the top portion to the horizontal support 224 and at the bottom portion to a bracket 228. The bracket 228 is secured to the end of the I-beam supports 110.

The discharge conveyor is of conventional design having a plurality of rollers 230 to support the doors after they have passed through the discharge rolls 220 and 218.

Reference is now made to FIG. 11 for a description of the control system which is used with the apparatus described in FIGS. 1 through 10. A control center 232 is provided to electrically actuate the various valves and switches which operate the cylinders and motors described hereinbefore in accordance with responses from switches and the like. An input signal is provided to commerce operation of the apparatus. A distribution valve 234 is provided to control the flow of hydraulic fluid into cylinder 64. A control line 236 connects the distribution valve 234 to the control center 232. A distribution valve 238 is provided to control the flow of hydraulic fluid into cylinder 98. A control line 240 connects the valve 238 with the control center 232. A distribution valve 242 controls the flow of hydraulic fluid into cylinder 96. A control line 244 connects the control center 232 with the valve 242.

A distribution valve 248 controls the flow of hydraulic fluid to a hydraulic cylinder 246 to operate the movement of the ejector lug 90. A similar hydraulic cylinder 246 and control valve similar to 248 is provided to operate the other ejector lug 86. A control line 250 connects the distribution valve 248 with the control center 232.

The level control sensor 138 for the hopper is connected to a micro switch 252. A control line 254 connects the micro switch 252 to the control center 232. A distribution valve 256 controls the flow of fluid pressure to either end of the hydraulic cylinder 116. A control line 258 connects the distribution valve 256 to the control center 232.

A distribution valve 260 controls the flow of hydraulic fluid to either end of the cylinder 166. A control line 262 connects the control center 232 with the distribution valve 260. Similarly, a distribution valve 264 controls the flow of hydraulic fluid to either end of the cylinder 170. A control line 266 connects the control center 232 with the distribution valve 264. A distribution valve 268 controls the flow of hydraulic fluid to either end of the cylinder 183. A control line 270 connects the control valve 268 with the control center 232.

A distribution valve 272 controls the flow of fluid pressure to either end of the cylinder 96. A control line 274 connects the distribution valve 272 with the control center 232. The motor 40 is connected to the control center 232 through control line 278. A solenoid switch 276 is provided to actuate operation of the stamping press 22. This solenoid switch 276 is connected to the control center 232 through a control line 278. A distribution valve 280 controls the flow of hydraulic fluid to either end of the hammer cylinder 208. This distribution valve 280 is connected to the control center 232 through control line 282.

Micro switches 284, 288 and 290 are positioned alongside of the path of travel of the shuttle platen 16. Control switch 284 is positioned so as to be contacted by the cam bar 120, control switch 288 is positioned so as to be in the path for actuation by the depending cam members 126, and the control switch 292 is positioned so as to be actuated by the cam member 127 (see FIG. 3). A control line 286 connects the switch 284 with the control center 232. A control line 290 connects the switch 288 with the control center 232. A control line 294 connects the switch 292 with the control center.

The operation of the apparatus will now be described with reference to the accompanying drawings. At the start of a cycle, the shuttle platen 16 is positioned completely beneath the hopper 14. In this initial position, the piston rods 68 are retracted permitting the bottom pair of doors in the hopper to fall onto the shuttle platen 16. 1f the hopper is not filled, the motor 40 will continue to be operated until a door in the top of the hopper contacts the level control sensor 138. When this occurs, the switch 252 is actuated to send a signal through control line 254 to the control center 232. Responsive to this signal, a signal is sent to motor 40 through control line 278 and the motor is stopped. Further feed of doors into the hopper is at this time discontinued.

When it is desirable to commence the hinge applying operation, an input signal is given to the control center 232. Alternately, in a continuous operation, no input signal need be given to the control center. It will automatically comment the operation after completion of the previous cycle. After the doors have dropped onto the shuttle platen, the control center sends a signal to each distribution valve 234 for each hydraulic cylinder 64 to extend their respective piston rods thereby engaging the lowermost door in each hopper. The control center 232 then sends a signal through control line 244 to the distribution valve 242 controlling the cylinder 96. The front stop member 92 is then moved upwardly in front of the doors. Simultaneously, the control center 232 sends a signal through line 250 to distribution valve 248 to cause the cylinder 246 to retract its piston rod thereby moving the ejector lug 90 toward the front of the platen. in addition the ejector lug 88 is moved to the front of the platen in a similar manner. The control center 232 also sends a signal through control line 240 to the distribution valve 238 to cause the cylinders 98 to extend piston rods 102 until the side blocks 100 push against the sides of the door and to the center of the shuttle platen against the separator blade 103.

The control center then signals the distribution valve 256 through control line 258 to extend the piston rod cylinder 116, thereby moving the shuttle platen forward. At this point, the cam bar 120 will come into contact with the control switch 284. Responsive thereto, a signal will be sent through line 286 to control center 232. This signal then causes the control center 232 to signal the distribution valve 234 to extend the piston rods 68 against the bottommost doors in the hopper.

As the shuttle platen moves forward, the first of a plurality of the depending cam members 126 contacts the cam follower for the control switch 288. Responsive thereto a signal is sent through the control line 290 to the control center 232. The control center 232 then signals the distribution valve 256 through control line 258 to stop the flow of fluid into the hydraulic cylinder 116, thereby stopping the movement of the shuttle platen. If desirable, a pair of micro switches can be used in place of the control switch 288, with the first control switch actuating a slow down of the flow of hydraulic fluid to the cylinder 116, and the second switch actuating a complete cessation of all flow offluid to the cylinder 116.

When the shuttle platen 16 has been stopped, a signal is sent from the control center 232 to the solenoid 276 through line 278. The solenoid 276 then actuates the stamping press 22 to stamp the nails from a hinge blank on the die block 186. 1m-

mediately thereafter, the control center sendsa signal through control line 274 to distribution valve 272 to actuate extension of the piston rod for cylinder 196, thereby pushing the hinge 26 down the rails 192. The hinge, thus stamped, will then be positioned beneath the hammer cylinder 208 on the magnetic hammer head 216. The control center 232 signals the distribution valve 280 through a control line 282 to cause hydraulic fluid to flow into the upper portion of the cylinder 208, thereby forcing the magnetic hammer head 16 downwardly. In this manner, the nails of the hinge are forced into the doors halves 24. The control center 232 then signals the distribution valve 256 through line 258 to continue Flow of hydraulic fluid into the cylinder 116 to continue movement of the shuttle platen.

After a movement of the shuttle platen through a predetermined distance, a second depending cam member 126 strikes the cam actuator for switch 288. At this point, a signal is sent through line 290 to the control center 232. Responsive to the signal, another hinge applying cycle takes place. These cycles continue until the desired number of hinges have been applied to the door halves 24. Upon further movement of the shuttle platen, the cam member 127 strikes the cam follower for the switch 292. Responsive thereto a signal is sent through control line 294 to control center 232. This signal then blocks all further operation of the hinge hammer press 18 and the stamping press 22. The cam member 127 is so positioned on the longitudinal bar 122 that it strikes the switch 292 when the shuttle platen is at the end of its run. The control center 232 then signals the distribution valve 242 to change the flow of fluid pressure into the cylinder 96, thereby lowering the front stop member 92. Simultaneously, a signal is sent through control line 250 to the distribution valve 248 to cause the piston rod of cylinder 246 to retract. The ejector lugs 88 and 90 then push the doors off the front of the shuttle platen and onto the discharge rollers 218 and 220. These rollers power the doors onto the discharge conveyor 28 for packing and shipment. If desirable, suitable means (not shown) can be provided to actuate the supplying of power to the rolls 218 and 220 when the doors are pushed therethrough.

After the doors have been ejected from the shuttle platen, the control center 232 then signals the distribution valve 256 to reverse the flow of fluid into the cylinder 116, thereby causing the shuttle platen to commence its rearward movement. Simultaneously, the control center 232 signals the distribution valve 248 to extend the piston rods for cylinders 246 to cause the ejector lugs 88 and 90 to return to their initial position at the very back of the shuttle platen. During this rearward movement, the control center 232 will not actuate the hinge hammer press 18 and the stamping press 22 even though the cam follower for the switch 288 may be struck by the depending cam members 126.

When the shuttle platen reaches the end of its rearward travel, the contact of the cam bar with the switch 284 will be broken. Responsive to this, a signal is sent through line 286 to the control center 232. The control center will then signal the distribution valve 256 to cease the flow of fluid into the hydraulic cylinder 116 thereby stopping the movement of the shuttle platen. At this point, the control center 232 will then signal the distribution valve 234 to reverse the flow of fluid to cylinders 64 to retract the respective piston rods. This action causes the dropping of the next two doors onto the shuttle platen. The cycle then begins anew.

The foregoing description of the operation of the invention has been given in rather simplified form. Obviously, in order to achieve maximum efficiency for operation of the apparatus, it would be necessary to co-oridinate the operation of the stamping press 22, the hinge hammer press 18 and the shuttle platen 16 so that a hinge is immediately applied to the door the instant the shuttle platen stops. In addition, various other devices such as hydraulic motors and controls therefor can be used to perfect the above described system.

The invention described above provides for a fast and economical method of manufacturing bifold doors and the like wherein the hinges are applied to the doors as fast as the doors can be fed to position in the manufacturing operation. With the invention, rates of producition as fast as 360 bifold doors per hour can be achieved. By the use of the invention, the hand operation of applying screws to hinges is eliminated. Further, the tolerances in the manufacture of hinge blank does not impede the mechanical operation. Thus inexpensive hinge blanks can be used in the apparatus described above.

By the invention the hinge blanks are oriented with respect to the barrel, stamped, then passed to the hinge applying operation. Thus after the stamping operation the hinge is in a predetermined orientation, and this orientation is maintained and used in positioning the stamped hinges on the hammer press.

Reasonable variation and modification are possible within the scope of the foregoing disclosure, the drawings, and the appended claims without departing from the spirit of the invention.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows.

1. A method of manufacturing a bifold door, said method comprising:

feeding a pair of door halves in juxtaposed relationship to a hinge applying zone;

providing a hinge member with a pair of leaves separated by a barrel to permit rotation of one leaf with respect to the other, each of said leaves having fastening members depending therefrom;

feeding said hinge member to said hinge applying zone above said door halves with said depending members and said barrel in apredetermined orientation with respect to said door halves; and

pressing said hinge member onto said door halves with each leaf being secured by said depending fastening members to one of said door halves and the barrel positioned therebetween, whereby said door halves are hinged together by said hinge.

' 2. A method of manufacturing a bifold door according to claim 1 further comprising the step of selectively moving said pair of door halves through said hinge applying area, and repeating the feeding and pressing steps to apply a plurality of hinges to said door;

3. A method of manufacturing'a bifold door according to claim 1 wherein said hinge is oriented with said depending members pointed downwardly.

4. A method of manufacturing a bifold door according to claim 1 wherein said depending fastening members are stamped from said leaves and said hinges are fed directly to said hinge applying zone after said stamping step.

5. A method of manufacturing a bifold door according to claim 1 wherein a hinge blank is first oriented and then fed to a stamping zone, and further comprising the stepof stamping said depending members from said leaves of said hinge blank.

6. A method of manufacturing a bifold door according to claim 5 wherein said hinge is fed directly to said hinge applying zone from said stamping zone in oriented relationship to said door.

7. A method of manufacturing a bifold door according to claim 5 wherein said hinge blank is oriented in folded condition with respect to the barrel.

8. A method for producing a bifold door having a pair of door halves hinged together at abutting edges thereof, said method comprising:

providing a source of hinge blanks having a pair of leaves with a barrel therebetween for rotatably mounting said leaves with respect to each other;

orienting said hinges with respect to said barrel;

feeding said hinges, seriatim, thus oriented, to a stamping zone;

stamping fastening members from each of said leaves in said stamping zone, said fastening members depending from each of said leaves;

moving said stamped hinges from said stamping zone to a pressing zone while maintaining a predetermined orienta tion for said stamped hinges;

moving a pair of elongated door halves in juxtaposed rela- 5 tionship through said pressing zone; and

pressing said stamped hinges onto said door halves such that the fastening members of each leaf engage a separate door half whereby said door halves are hinged together.

9. A method for producing a bifold door according to claim 8 wherein said door halves are moved intermittently through said pressing zone.

10. An apparatus for hinging a pair of planar wooden members together, said apparatus comprising:

means for selectively moving pairs of elongated wooden members in juxtaposed relationship along a line;

hinge retainer means positioned along said line;

means for feeding hinges to said hinge retainer means in a predetermined relationship to a pair of elongated wooden members, each of said hinges having a pair of leaves and a barrel therebetween, each of said leaves having fastening members depending therefrom; and

means for pressing hinges onto said wooden members as said wooden members move along said line with said fastening members of each leaf engaging one of said wooden members, whereby said wooden members are hinged together.

11. An apparatus for hinging a pair of planar wooden members together according to claim 10 further comprising hopper means for dispensing said planar members in pairs to said moving means.

12. An apparatus for hinging a pair of planar wooden members together according to claim 11 wherein said selective moving means comprises: a platform base having a flat upper surface to support said planar members in juxtaposed relationship; guide means for said platform base to define the movement of said platform base along said line, said platform base being movable beneath said hopper means to receive planar members dispensed therefrom; and said hopper means having a pair of chambers for holding two sets of planar members; and means to dispense one of said planar members from each of said chambers onto said platform base when said platform base is positioned beneath said hopper means.

13. An apparatus for hinging a pair of planar members together according to claim 12 wherein said platform base has a thin divider member in a central portion thereof, dividing said platform base into two sides; and means are provided on said moving means to push said wooden members against said thin divider members.

14. An apparatus for hinging a pair of planar members together according to claim 13 wherein said moving means further comprises means to align said wooden members longitudinally on said platform base with respect to each other. 55 15. An apparatus for hinging a pair of planar wooden members together according to claim 12 further comprising a discharge conveyor at the end of said line of movement of said platform base; and means on said moving means for ejecting said doors from said platform base onto said discharge conveyor when said platform base reaches the discharge end of said line.

16 An apparatus for hinging a pair of planar wooden members together according to claim 10 wherein said selective moving means comprises a platform base having a flat upper surface to support said planar member in juxtaposed relationship; and guide means to define the movement of said platform base along said line, said platform base being movable beneath said hinge retainer means.

17. An apparatus for hinging a pair of planar wooden mem- 70 bers together according to claim 16 wherein said hinge retainer means releasably support said hinges such that said hinges are released when forced downwardly with respect to said hinge retainer means; and said pressing means comprises a hammer head having a bottom surface to conform with the shape of the upper surface of said hinges; means mounting said hammer head for movement downwardly between said hinge retainer means to force said hinges downwardly with respect to said hinge retainer means, thereby releasing said hinges from said hinge retainer means; and means to hold said hinges in contact with said hammer head lower surface as said hammer head moves downwardly to press said hinges onto said wooden members after said hinges have been released by said hinge retaining means.

18. An apparatus for hinging a pair of planar wooden members together according to claim 17 wherein said hinge holding means on said hammer head comprises magnetic means in said hammer head to magnetically hold said hinges in contact with said hammer head lower surface.

19. An apparatus for hinging a pair of planar wooden members together according to claim and further comprising means to form said fastening members on said hinge leaves; and said hinge feeding means move said hinges from said forming means to said hinge retainer means.

20. An apparatus for hinging a pair of planar wooden members together according to claim 19 further comprising means to supply hinges in a predetermined orientation to said forming means.

21. An apparatus for hinging a pair of planar wooden members together according to claim 19 wherein said hinge supply means comprises a track,; means to move hinge blanks along said track; means along said track for folding and orienting said hinge blanks with the barrel of said hinge blanks aligned with the direction of movement of said hinge blanks along said track; and means at an endportion of said track for raising said hinge blanks onto their respective barrels while maintaining the hinge blanks in folded condition.

22. An apparatus for hinging a pair of wooden members together according to claim 21 wherein said hinge supply means further comprises means to open said hinges to a flat position as said hinge blanks are fed to said forming means; and means to pass said hinges, raised on the barrels thereof, to said opening means.

23. An apparatus for hinging a pair of planar wooden members together according to claim 19 wherein said forming means comprises astamping press.

24. An apparatus for hinging a pair of planar wooden members together according to claim 10 wherein said hinge feeding means comprises a track; means to move hinge blanks along said track;

means along said track for orienting said hinge blanks in flat folded condition with the barrel of said hinge blanks facing a side of said track and aligned with the direction of movement of said hinge blanks along said track; and means at an end portion of said track for raising said hinge blanks onto their respective barrels while maintaining said hinge blanks in flat folded condition.

25. An apparatus for hinging a pair of planar wooden members together according to claim 24 wherein said hinge feeding means further comprises means to open said hinges to a flat position, and means to pass said hinges, resting on the barrels thereof, to said opening means.

26. In an apparatus for hinging door halves, a means for orienting hinge blanks having a pair of leaves rotatably joined by a barrel therebetween, said orienting means comprising:

a track;

means to move hinge blanks along said track;

means along said track for orienting said hinge blanks in flat folded condition with the barrel of said hinge blanks facing a side of said track and aligned with the direction of movement of said hinges along said track;

means at an end portion of said track for raising said hinge blanks on their respective barrels while maintaining said hinge blanks in flat folded condition.

27 An apparatus for hinging door halves according to claim 26 further comprising means to open said hinges to a fiat position, and means to pass said hinges, resting on the barrels thereof, to said opening means.

28. An apparatus for hinging door halves according to claim 26 and further comprising a bowl and wherein said track is convolutely shaped around said bowl, and said moving means is a vibrator, said hinges being moved from a central area of said bowl onto and up said track. 

1. A method of manufacturing a bifold door, said method comprising: feeding a pair of door halves in juxtaposed relationship to a hinge applying zone; providing a hinge member with a pair of leaves separated by a barrel to permit rotation of one leaf with respect to the other, each of said leaves having fastening members depending therefrom; feeding said hinge member to said hinge applying zone above said door halves with said depending members and said barrel in a predetermined orientation with respect to said door halves; and pressing said hinge member onto said door halves with each leaf being secured by said depending fastening members to one of said door halves and the barrel positioned therebetween, whereby said door halves are hinged together by said hinge.
 2. A method of manufacturing a bifold door according to claim 1 further comprising the step of selectively moving said pair of door halves through said hinge applying area, and repeating the feeding and pressing steps to apply a plurality of hinges to said door.
 3. A method of manufacturing a bifold door according to claim 1 wherein said hinge is oriented with said depending members pointed downwardly.
 4. A method of manufacturing a bifold door according to claim 1 wherein said depending fastening members are stamped from said leaves and said hinges are fed directly to said hinge applying zone after said stamping step.
 5. A method of manufacturing a bifold door according to claim 1 wherein a hinge blank is first oriented and then fed to a stamping zone, and further comprising the step of stamping said depending members from said leaves of said hinge blank.
 6. A method of manufacturing a bifold door according to claim 5 wherein said hinge is fed directly to said hinge applying zone from said stamping zone in oriented relationship to said door.
 7. A method of manufacturing a bifold door according to claim 5 wherein said hinge blank is oriented in folded condition with respect to the barrel.
 8. A method for producing a bifold door having a pair of door halves hinged together at abutting edges thereof, said method comprising: providing a source of hinge blanks having a pair of leaves with a barrel therebetween for rotatably mounting said leaves with respect to each other; orienting said hinges with respect to said barrel; feeding said hinges, seriatim, thus oriented, to a stamping zone; stamping fastening members from each of said leaves in said stamping zone, said fastening members depending from each of said leaves; moving said stamped hinges from said stamping zone to a pressing zone while maintaining a predetermined orientation for said stamped hinges; moving a pair of elongated door halves in juxtaposed relationship through said pressing zone; and pressing said stamped hinges onto said door halves such that the fastening members of each leaf engage a separate door half whereby said door halves are hinged together.
 9. A method for producing a bifold door according to claim 8 wherein said door halves are moved intermittently through said pressing zone.
 10. An apparatus for hinging a pair of planar wooden members together, said apparatus comprising: means for selectively moving pairs of elongated wooden members in juxtaposed relationship along a line; hinge retainer means positioned along said line; means for feeding hinges to said hinge retainer means in a predetermined relationship to a pair of elongated wooden members, each of said hinges having a pair of leaves and a barrel therebetween, each of said leaves having fastening members depending therefrom; and means for pressing hinges onto said wooden members as said wooden members move along said line with said fastening members of each leaf engaging one of said wooden members, whereby said wooden members are hinged together.
 11. An apparatus for hinging a pair of planar wooden members together according to claim 10 further comprising hopper means for dispensing said planar members in pairs to said moving means.
 12. An apparatus for hinging a pair of planar wooden members together according to claim 11 wherein said selective moving means comprises: a platform base having a flat upper surface to support said planar members in juxtaposed relationship; guide means for said platform base to define the movement of said platform base along said line, said platform base being movable beneath said hopper means to receive planar members dispensed therefrom; and said hopper means having a pair of chambers for holding two sets of planar members; and means to dispense one of said planar members from each of said chambers onto said platform base when said platform base is positioned beneath said hopper means.
 13. An apparatus for hinging a pair of planar members together according to claim 12 wherein said platform base has a thin divider member in a central portion thereof, dividing said platform base into two sides; and means are provided on said moving means to push said wooden members against said thin divider members.
 14. An apparatus for hinging a pair of planar members together according to claim 13 wherein said moving means further comprises means to align said wooden members longitudinally on said platform base with respect to each other.
 15. An apparatus for hinging a pair of planar wooden members together according to claim 12 further comprising a discharge conveyor at the end of said line of movement of said platform base; and means on said moving means for ejecting said doors from said platform base onto said discharge conveyor when said platform base reaches the discharge end of said line. 16 An apparatus for hinging a pair of planar wooden members together according to claim 10 wherein said selective moving means comprises a platform base having a flat upper surface to support said planar member in juxtaposed relationship; and guide means to define the movement of said platform base along said line, said platform base being movable beneath said hinge retainer means.
 17. An apparatus for hinging a pair of planar wooden members together according to claim 16 wherein said hinge retainer means releasably support said hinges such that said hinges are released when forced downwardly with respect to said hinge retainer means; and said pressing means comprises a hammer head having a bottom surface to conform with the shape of the upper surface of said hinges; means mounting said hammer head for movement downwardly between said hinge retainer means to force said hinges downwardly with respect to said hinge retainer means, thereby releasing said hinges from said hinge retainer means; and means to hold said hinges in contact with said hammer head lower surface as said hammer head moves downwardly to press said hinges onto said wooden members after said hinges have been released by said hinge retaining means.
 18. An apparatus for hinging a pair of planar wooden members together according to claim 17 wherein said hinge holding means on said hammer head comprises magnetic means in said hammer head to magnetically hold said hinges in contact with said hammer head lower surface.
 19. An apparatus for hinging a pair of planar wooden members together according to claim 10 and further comprising means to form said fastening members on said hinge leaves; and said hinge feeding means move said hinges from said forming means to said hinge retainer means.
 20. An apparatus for hinging a pair of planar wooden members together according to claim 19 further comprising means to supply hinges in a predetermined orientation to said forming means.
 21. An apparatus for hinging a pair of planar wooden members together according to claim 19 wherein said hinge supply means comprises a track,; means to move hinge blanks along said track; means along said track for folding and orienting said hinge blanks with the barrel of said hinge blanks aligned with the direction of movement of said hinge blanks along said track; and means at an end portion of said track for raising said hinge blanks onto their respective barrels while maintaining the hinge blanks in folded condition.
 22. An apparatus for hinging a pair of wooden members together according to claim 21 wherein said hinge supply means further comprises means to open said hinges to a flat position as said hinge blanks are fed to said forming means; and means to pass said hinges, raised on the barrels thereof, to said opening means.
 23. An apparatus for hinging a pair of planar wooden members together according to claim 19 wherein said forming means comprises a stamping press.
 24. An apparatus for hinging a pair of planar wooden members together according to claim 10 wherein said hinge feeding means comprises a track; means to move hinge blanks along said track; means along said track for orienting said hinge blanks in flat folded condition with the barrel of said hinge blanks facing a side of said track and aligned with the direction of movement of said hinge blanks along said track; and means at an end portion of said track for raising said hinge blanks onto their respective barrels while maintaining said hinge blanks in flat folded condition.
 25. An apparatus for hinging a pair of planar wooden members together according to claim 24 wherein said hinge feeding means further comprises means to open said hinges to a flat position, and means to pass said hinges, resting on the barrels thereof, to said opening means.
 26. In an apparatus for hinging door halves, a means for orienting hinge blanks having a pair of leaves rotatably joined by a barrel therebetween, said orienting means comprising: a track; means to move hinge blanks along said track; means along said track for orienting said hinge blanks in flat folded condition with the barrel of said hinge blanks facing a side of said track and aligned with the direction of movement of said hinges along said track; means at an end portion of said track for raising said hinge blanks on their respective barrels while maintaining said hinge blanks in flat folded condition. 27 An apparatus for hinging door halves according to claim 26 further comprising means to open said hinges to a flat position, and means to pass said hinges, resting on the barrels thereof, to said opening means.
 28. An apparatus for hinging door halves according to claim 26 and further comprising a bowl and wherein said track is convolutely shaped around said bowl, and said moving means is a vibrator, said hinges being moved from a central area of said bowl onto and up said track. 